EP1587861B1 - Foamable interpolymer resin particles containing limonene as a blowing aid - Google Patents
Foamable interpolymer resin particles containing limonene as a blowing aid Download PDFInfo
- Publication number
- EP1587861B1 EP1587861B1 EP04704842A EP04704842A EP1587861B1 EP 1587861 B1 EP1587861 B1 EP 1587861B1 EP 04704842 A EP04704842 A EP 04704842A EP 04704842 A EP04704842 A EP 04704842A EP 1587861 B1 EP1587861 B1 EP 1587861B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- weight
- particles
- resin particles
- vinyl aromatic
- limonene
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000002245 particle Substances 0.000 title claims abstract description 131
- XMGQYMWWDOXHJM-UHFFFAOYSA-N limonene Chemical compound CC(=C)C1CCC(C)=CC1 XMGQYMWWDOXHJM-UHFFFAOYSA-N 0.000 title claims abstract description 64
- 229920005989 resin Polymers 0.000 title claims abstract description 63
- 239000011347 resin Substances 0.000 title claims abstract description 63
- 229940087305 limonene Drugs 0.000 title claims abstract description 32
- 235000001510 limonene Nutrition 0.000 title claims abstract description 30
- 238000007664 blowing Methods 0.000 title description 28
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 57
- 229920000098 polyolefin Polymers 0.000 claims abstract description 43
- 239000004604 Blowing Agent Substances 0.000 claims abstract description 42
- -1 polyethylene Polymers 0.000 claims abstract description 30
- XMGQYMWWDOXHJM-JTQLQIEISA-N (+)-α-limonene Chemical compound CC(=C)[C@@H]1CCC(C)=CC1 XMGQYMWWDOXHJM-JTQLQIEISA-N 0.000 claims abstract description 25
- 239000004698 Polyethylene Substances 0.000 claims abstract description 14
- 229920000573 polyethylene Polymers 0.000 claims abstract description 14
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 20
- 229920001577 copolymer Polymers 0.000 claims description 19
- 239000000203 mixture Substances 0.000 claims description 17
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 claims description 14
- QWTDNUCVQCZILF-UHFFFAOYSA-N isopentane Chemical compound CCC(C)C QWTDNUCVQCZILF-UHFFFAOYSA-N 0.000 claims description 12
- CRSOQBOWXPBRES-UHFFFAOYSA-N neopentane Chemical compound CC(C)(C)C CRSOQBOWXPBRES-UHFFFAOYSA-N 0.000 claims description 10
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 claims description 9
- RGSFGYAAUTVSQA-UHFFFAOYSA-N Cyclopentane Chemical compound C1CCCC1 RGSFGYAAUTVSQA-UHFFFAOYSA-N 0.000 claims description 8
- 229920001519 homopolymer Polymers 0.000 claims description 7
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 claims description 6
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 claims description 6
- NNPPMTNAJDCUHE-UHFFFAOYSA-N isobutane Chemical compound CC(C)C NNPPMTNAJDCUHE-UHFFFAOYSA-N 0.000 claims description 6
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 claims description 6
- DDMOUSALMHHKOS-UHFFFAOYSA-N 1,2-dichloro-1,1,2,2-tetrafluoroethane Chemical compound FC(F)(Cl)C(F)(F)Cl DDMOUSALMHHKOS-UHFFFAOYSA-N 0.000 claims description 4
- HRYZWHHZPQKTII-UHFFFAOYSA-N chloroethane Chemical compound CCCl HRYZWHHZPQKTII-UHFFFAOYSA-N 0.000 claims description 4
- 229940087091 dichlorotetrafluoroethane Drugs 0.000 claims description 4
- 229960003750 ethyl chloride Drugs 0.000 claims description 4
- DMEGYFMYUHOHGS-UHFFFAOYSA-N heptamethylene Natural products C1CCCCCC1 DMEGYFMYUHOHGS-UHFFFAOYSA-N 0.000 claims description 4
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 claims description 4
- 230000000704 physical effect Effects 0.000 claims description 4
- VOPWNXZWBYDODV-UHFFFAOYSA-N Chlorodifluoromethane Chemical compound FC(F)Cl VOPWNXZWBYDODV-UHFFFAOYSA-N 0.000 claims description 3
- PMPVIKIVABFJJI-UHFFFAOYSA-N Cyclobutane Chemical compound C1CCC1 PMPVIKIVABFJJI-UHFFFAOYSA-N 0.000 claims description 3
- 239000004338 Dichlorodifluoromethane Substances 0.000 claims description 3
- NEHMKBQYUWJMIP-NJFSPNSNSA-N chloro(114C)methane Chemical compound [14CH3]Cl NEHMKBQYUWJMIP-NJFSPNSNSA-N 0.000 claims description 3
- PXBRQCKWGAHEHS-UHFFFAOYSA-N dichlorodifluoromethane Chemical compound FC(F)(Cl)Cl PXBRQCKWGAHEHS-UHFFFAOYSA-N 0.000 claims description 3
- 235000019404 dichlorodifluoromethane Nutrition 0.000 claims description 3
- 229940042935 dichlorodifluoromethane Drugs 0.000 claims description 3
- UMNKXPULIDJLSU-UHFFFAOYSA-N dichlorofluoromethane Chemical compound FC(Cl)Cl UMNKXPULIDJLSU-UHFFFAOYSA-N 0.000 claims description 3
- 229940099364 dichlorofluoromethane Drugs 0.000 claims description 3
- 239000001282 iso-butane Substances 0.000 claims description 3
- 235000013847 iso-butane Nutrition 0.000 claims description 3
- 229940073584 methylene chloride Drugs 0.000 claims description 3
- CYRMSUTZVYGINF-UHFFFAOYSA-N trichlorofluoromethane Chemical compound FC(Cl)(Cl)Cl CYRMSUTZVYGINF-UHFFFAOYSA-N 0.000 claims description 3
- 229940029284 trichlorofluoromethane Drugs 0.000 claims description 3
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 2
- 125000000545 (4R)-limonene group Chemical group 0.000 claims 1
- 125000003011 styrenyl group Chemical group [H]\C(*)=C(/[H])C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 claims 1
- 229930195733 hydrocarbon Natural products 0.000 abstract description 11
- 150000002430 hydrocarbons Chemical class 0.000 abstract description 10
- 239000004215 Carbon black (E152) Substances 0.000 abstract description 7
- 238000011065 in-situ storage Methods 0.000 abstract description 5
- 239000004793 Polystyrene Substances 0.000 abstract description 4
- 229920002223 polystyrene Polymers 0.000 abstract description 4
- 239000003205 fragrance Substances 0.000 abstract description 2
- 239000000178 monomer Substances 0.000 description 34
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 21
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 21
- YNQLUTRBYVCPMQ-UHFFFAOYSA-N Ethylbenzene Chemical compound CCC1=CC=CC=C1 YNQLUTRBYVCPMQ-UHFFFAOYSA-N 0.000 description 18
- 238000000034 method Methods 0.000 description 10
- 239000003999 initiator Substances 0.000 description 9
- 239000004014 plasticizer Substances 0.000 description 9
- 229920000642 polymer Polymers 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 8
- 239000005977 Ethylene Substances 0.000 description 8
- 239000012736 aqueous medium Substances 0.000 description 8
- 239000003431 cross linking reagent Substances 0.000 description 8
- 231100001244 hazardous air pollutant Toxicity 0.000 description 8
- 238000005470 impregnation Methods 0.000 description 6
- 238000006116 polymerization reaction Methods 0.000 description 6
- 229920013716 polyethylene resin Polymers 0.000 description 5
- 239000000725 suspension Substances 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 4
- 238000005187 foaming Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000012508 resin bead Substances 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 229920005992 thermoplastic resin Polymers 0.000 description 4
- 239000001993 wax Substances 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 3
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 3
- 238000009835 boiling Methods 0.000 description 3
- 239000001506 calcium phosphate Substances 0.000 description 3
- 239000002270 dispersing agent Substances 0.000 description 3
- 239000006260 foam Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 230000000379 polymerizing effect Effects 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 3
- MYRTYDVEIRVNKP-UHFFFAOYSA-N 1,2-Divinylbenzene Chemical compound C=CC1=CC=CC=C1C=C MYRTYDVEIRVNKP-UHFFFAOYSA-N 0.000 description 2
- KNKRKFALVUDBJE-UHFFFAOYSA-N 1,2-dichloropropane Chemical compound CC(Cl)CCl KNKRKFALVUDBJE-UHFFFAOYSA-N 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 2
- 239000007900 aqueous suspension Substances 0.000 description 2
- WQAQPCDUOCURKW-UHFFFAOYSA-N butanethiol Chemical compound CCCCS WQAQPCDUOCURKW-UHFFFAOYSA-N 0.000 description 2
- 229910000389 calcium phosphate Inorganic materials 0.000 description 2
- 235000011010 calcium phosphates Nutrition 0.000 description 2
- 235000020971 citrus fruits Nutrition 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- XZTWHWHGBBCSMX-UHFFFAOYSA-J dimagnesium;phosphonato phosphate Chemical compound [Mg+2].[Mg+2].[O-]P([O-])(=O)OP([O-])([O-])=O XZTWHWHGBBCSMX-UHFFFAOYSA-J 0.000 description 2
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical compound [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- 229920001038 ethylene copolymer Polymers 0.000 description 2
- 235000013373 food additive Nutrition 0.000 description 2
- 239000002778 food additive Substances 0.000 description 2
- 150000008282 halocarbons Chemical class 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229920000609 methyl cellulose Polymers 0.000 description 2
- 239000001923 methylcellulose Substances 0.000 description 2
- 235000010981 methylcellulose Nutrition 0.000 description 2
- 239000003505 polymerization initiator Substances 0.000 description 2
- 229920001955 polyphenylene ether Polymers 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 239000000375 suspending agent Substances 0.000 description 2
- VZGDMQKNWNREIO-UHFFFAOYSA-N tetrachloromethane Chemical compound ClC(Cl)(Cl)Cl VZGDMQKNWNREIO-UHFFFAOYSA-N 0.000 description 2
- KDGNCLDCOVTOCS-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy propan-2-yl carbonate Chemical compound CC(C)OC(=O)OOC(C)(C)C KDGNCLDCOVTOCS-UHFFFAOYSA-N 0.000 description 1
- LNAZSHAWQACDHT-XIYTZBAFSA-N (2r,3r,4s,5r,6s)-4,5-dimethoxy-2-(methoxymethyl)-3-[(2s,3r,4s,5r,6r)-3,4,5-trimethoxy-6-(methoxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6r)-4,5,6-trimethoxy-2-(methoxymethyl)oxan-3-yl]oxyoxane Chemical compound CO[C@@H]1[C@@H](OC)[C@H](OC)[C@@H](COC)O[C@H]1O[C@H]1[C@H](OC)[C@@H](OC)[C@H](O[C@H]2[C@@H]([C@@H](OC)[C@H](OC)O[C@@H]2COC)OC)O[C@@H]1COC LNAZSHAWQACDHT-XIYTZBAFSA-N 0.000 description 1
- RIPYNJLMMFGZSX-UHFFFAOYSA-N (5-benzoylperoxy-2,5-dimethylhexan-2-yl) benzenecarboperoxoate Chemical compound C=1C=CC=CC=1C(=O)OOC(C)(C)CCC(C)(C)OOC(=O)C1=CC=CC=C1 RIPYNJLMMFGZSX-UHFFFAOYSA-N 0.000 description 1
- ZUDLIFVTNPYZJH-UHFFFAOYSA-N 1,1,2,2-tetraphenylethylbenzene Chemical compound C1=CC=CC=C1C(C(C=1C=CC=CC=1)(C=1C=CC=CC=1)C=1C=CC=CC=1)C1=CC=CC=C1 ZUDLIFVTNPYZJH-UHFFFAOYSA-N 0.000 description 1
- GDEQPEBFOWYWSA-UHFFFAOYSA-N 1,2-dimethyl-3-propan-2-ylbenzene Chemical group CC(C)C1=CC=CC(C)=C1C GDEQPEBFOWYWSA-UHFFFAOYSA-N 0.000 description 1
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 1
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- YAJYJWXEWKRTPO-UHFFFAOYSA-N 2,3,3,4,4,5-hexamethylhexane-2-thiol Chemical compound CC(C)C(C)(C)C(C)(C)C(C)(C)S YAJYJWXEWKRTPO-UHFFFAOYSA-N 0.000 description 1
- OZAIFHULBGXAKX-UHFFFAOYSA-N 2-(2-cyanopropan-2-yldiazenyl)-2-methylpropanenitrile Chemical compound N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- XMNIXWIUMCBBBL-UHFFFAOYSA-N 2-(2-phenylpropan-2-ylperoxy)propan-2-ylbenzene Chemical compound C=1C=CC=CC=1C(C)(C)OOC(C)(C)C1=CC=CC=C1 XMNIXWIUMCBBBL-UHFFFAOYSA-N 0.000 description 1
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- SBYMUDUGTIKLCR-UHFFFAOYSA-N 2-chloroethenylbenzene Chemical compound ClC=CC1=CC=CC=C1 SBYMUDUGTIKLCR-UHFFFAOYSA-N 0.000 description 1
- WDQMWEYDKDCEHT-UHFFFAOYSA-N 2-ethylhexyl 2-methylprop-2-enoate Chemical compound CCCCC(CC)COC(=O)C(C)=C WDQMWEYDKDCEHT-UHFFFAOYSA-N 0.000 description 1
- BIISIZOQPWZPPS-UHFFFAOYSA-N 2-tert-butylperoxypropan-2-ylbenzene Chemical compound CC(C)(C)OOC(C)(C)C1=CC=CC=C1 BIISIZOQPWZPPS-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 239000004342 Benzoyl peroxide Substances 0.000 description 1
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 1
- 239000004709 Chlorinated polyethylene Substances 0.000 description 1
- 241000207199 Citrus Species 0.000 description 1
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 1
- IEPRKVQEAMIZSS-UHFFFAOYSA-N Di-Et ester-Fumaric acid Natural products CCOC(=O)C=CC(=O)OCC IEPRKVQEAMIZSS-UHFFFAOYSA-N 0.000 description 1
- IEPRKVQEAMIZSS-WAYWQWQTSA-N Diethyl maleate Chemical compound CCOC(=O)\C=C/C(=O)OCC IEPRKVQEAMIZSS-WAYWQWQTSA-N 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 1
- YIVJZNGAASQVEM-UHFFFAOYSA-N Lauroyl peroxide Chemical compound CCCCCCCCCCCC(=O)OOC(=O)CCCCCCCCCCC YIVJZNGAASQVEM-UHFFFAOYSA-N 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- 229920001890 Novodur Polymers 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- 241000276498 Pollachius virens Species 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- YMOONIIMQBGTDU-VOTSOKGWSA-N [(e)-2-bromoethenyl]benzene Chemical compound Br\C=C\C1=CC=CC=C1 YMOONIIMQBGTDU-VOTSOKGWSA-N 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 125000005250 alkyl acrylate group Chemical group 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- 125000000751 azo group Chemical group [*]N=N[*] 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 0.000 description 1
- SQHOHKQMTHROSF-UHFFFAOYSA-N but-1-en-2-ylbenzene Chemical compound CCC(=C)C1=CC=CC=C1 SQHOHKQMTHROSF-UHFFFAOYSA-N 0.000 description 1
- MPMBRWOOISTHJV-UHFFFAOYSA-N but-1-enylbenzene Chemical compound CCC=CC1=CC=CC=C1 MPMBRWOOISTHJV-UHFFFAOYSA-N 0.000 description 1
- NTXGQCSETZTARF-UHFFFAOYSA-N buta-1,3-diene;prop-2-enenitrile Chemical compound C=CC=C.C=CC#N NTXGQCSETZTARF-UHFFFAOYSA-N 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- QYMGIIIPAFAFRX-UHFFFAOYSA-N butyl prop-2-enoate;ethene Chemical compound C=C.CCCCOC(=O)C=C QYMGIIIPAFAFRX-UHFFFAOYSA-N 0.000 description 1
- TUZBYYLVVXPEMA-UHFFFAOYSA-N butyl prop-2-enoate;styrene Chemical compound C=CC1=CC=CC=C1.CCCCOC(=O)C=C TUZBYYLVVXPEMA-UHFFFAOYSA-N 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 235000010216 calcium carbonate Nutrition 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- LSXWFXONGKSEMY-UHFFFAOYSA-N di-tert-butyl peroxide Chemical compound CC(C)(C)OOC(C)(C)C LSXWFXONGKSEMY-UHFFFAOYSA-N 0.000 description 1
- 239000000539 dimer Substances 0.000 description 1
- LDCRTTXIJACKKU-ARJAWSKDSA-N dimethyl maleate Chemical compound COC(=O)\C=C/C(=O)OC LDCRTTXIJACKKU-ARJAWSKDSA-N 0.000 description 1
- WNAHIZMDSQCWRP-UHFFFAOYSA-N dodecane-1-thiol Chemical compound CCCCCCCCCCCCS WNAHIZMDSQCWRP-UHFFFAOYSA-N 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 229920006245 ethylene-butyl acrylate Polymers 0.000 description 1
- 229920005680 ethylene-methyl methacrylate copolymer Polymers 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- 230000002794 monomerizing effect Effects 0.000 description 1
- 229930003658 monoterpene Natural products 0.000 description 1
- 235000002577 monoterpenes Nutrition 0.000 description 1
- RKISUIUJZGSLEV-UHFFFAOYSA-N n-[2-(octadecanoylamino)ethyl]octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(=O)NCCNC(=O)CCCCCCCCCCCCCCCCC RKISUIUJZGSLEV-UHFFFAOYSA-N 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- 150000001451 organic peroxides Chemical class 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 239000002304 perfume Substances 0.000 description 1
- 229920001084 poly(chloroprene) Polymers 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920001195 polyisoprene Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 229920005990 polystyrene resin Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 238000010557 suspension polymerization reaction Methods 0.000 description 1
- OPQYOFWUFGEMRZ-UHFFFAOYSA-N tert-butyl 2,2-dimethylpropaneperoxoate Chemical compound CC(C)(C)OOC(=O)C(C)(C)C OPQYOFWUFGEMRZ-UHFFFAOYSA-N 0.000 description 1
- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 1
- WMXCDAVJEZZYLT-UHFFFAOYSA-N tert-butylthiol Chemical compound CC(C)(C)S WMXCDAVJEZZYLT-UHFFFAOYSA-N 0.000 description 1
- 229910000391 tricalcium phosphate Inorganic materials 0.000 description 1
- 235000019731 tricalcium phosphate Nutrition 0.000 description 1
- 229940078499 tricalcium phosphate Drugs 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F255/00—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
- C08F255/02—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having two or three carbon atoms
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/16—Making expandable particles
- C08J9/18—Making expandable particles by impregnating polymer particles with the blowing agent
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/141—Hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/149—Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/16—Making expandable particles
- C08J9/20—Making expandable particles by suspension polymerisation in the presence of the blowing agent
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
- C08L25/02—Homopolymers or copolymers of hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J2203/142—Halogenated saturated hydrocarbons, e.g. H3C-CF3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
- C08J2325/02—Homopolymers or copolymers of hydrocarbons
- C08J2325/04—Homopolymers or copolymers of styrene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2351/00—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2351/06—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2425/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
Definitions
- the present invention relates to foamable interpolymer resin particles comprised of polyolefins, e.g.polyethylene, and polymerized vinyl aromatic resin. More particularly, the present invention relates to foamable interpolymer resin particles comprised of a volatile blowing agent ranging from between 1.5% to 20 wt% based on the weight of the particles and 0.1 to 5 parts, preferably 0.1 to 1.0 part, by weight limonene, based on 100 parts by weight of the foamable interpolymer resin particles, as a plasticizer or blowing aid.
- a volatile blowing agent ranging from between 1.5% to 20 wt% based on the weight of the particles and 0.1 to 5 parts, preferably 0.1 to 1.0 part, by weight limonene, based on 100 parts by weight of the foamable interpolymer resin particles, as a plasticizer or blowing aid.
- U.S. Patent No. 3,959,189 issued to Kitamori and assigned to Sekisui Kaseihin Kabushiki Kaisha, discloses a process for producing polyethylene resin particles which comprises suspending in an aqueous medium polyethylene resin particles, adding to the suspension 30 to 100% by weight based on the weight of the particles of a styrene monomer and an initiator for polymerizing the monomer, and polymerizing the monomer inside the polyethylene resin particles.
- the particles can then be made foamable by impregnating them with a blowing agent, preferably after the polymerization of the styrene monomer and the cross-linking of the polyethylene resin.
- the blowing agent generally is a volatile blowing agent, i.e.
- aliphatic hydrocarbons such as n-propane, n-butane, iso-butane, n-pentane, iso-pentane, n-hexane and neopentane; or cycloaliphatic hydrocarbons such as cyclobutane and cyclopentane; and halogenated hydrocarbons such as methyl chloride, ethyl chloride, methylene chloride, trichlorofluoromethane, dichlorofluoromethane, dichlorodifluoromethane, chlorodifluoromethane and dichlorotetrafluoroethane, etc. in an amount between 5 to 20% by weight based on the weight of the polyethylene-polystyrene resin particles.
- U.S. Patent Nos. 4,303,756 and 4,303,757 issued to Kajimura, et al. and assigned to Sekisui Kaseihin Kogyo Kabushiki Kaisha disclose a process for producing expandable thermoplastic resin beads where a vinyl aromatic monomer is polymerized onto the backbone of the polypropylene; and introducing a blowing agent into the thermoplastic resin beads.
- the blowing agent is the same as that taught in the aforesaid U.S. Patent No. 4,782,098 .
- U.S. Patent No. 4,429,059 issued to Ozutsumi, et al. and assigned to Sekisui Kaseihin Kogyo Kabushiki Kaisha discloses a process for producing foamable polyolefin particles comprising adding a mixture of 3 to 15 parts by weight of a blowing agent and 0.5 to 5 parts by weight of a blowing aid to 100 parts by weight of polyolefin particles.
- Column 2, lines 63-66 teach that the blowing aid causes the interior of the particles to be in a plastic state to facilitate the foaming of the particles.
- Representative blowing aids used as a plasticizer are benzene, toluene, xylene, trichlene, perchlene, cyclohexane, carbon tetrachloride, etc.
- the particles of the prior art are impregnated with a blowing agent, or in the instance of the aforesaid U.S. Patent No. 4,429,059 with a blowing agent and a blowing aid.
- the blowing agents are generally "volatile" hydrocarbons, and the blowing aids are generally considered as hazardous air pollutants (HAPS), as found in the 1990 Federal Clean Air Act Amendments, Section 112.
- HAPS hazardous air pollutants
- the blowing agents and blowing aids generally are emitted into the environment during the processing and foaming of the particles. Both the producer and the converter of the particles may be forced to reduce the emissions to acceptable regulatory levels, which would involve investing in complicated equipment for collecting the emitted hydrocarbons.
- blowing aid that is not considered to be a hazardous air pollutant and that does not have an offensive odor while still providing excellent foamability and molding fusability properties.
- JP 11080412 (Achilles Corporation)(Entitled: "Heat-resistant cellular styrene polymer-polyoxyphenylene”) teaches the use of limonene in a blend of styrenic resin and a polyphenylene ether-based resin.
- the abstract teaches that the particles contain 3-15 parts volatile blowing agent-impregnated polymer particles consisting of 50-90 parts styrene polymers and 10-50 parts poly(phenylene ethers) and 0.1-5 parts (for 100 parts polymer particles) limonene.
- a composition containing polystyrene, poly(phenylene ether), ethylenebis(stearamide), pentane, and limonene was extruded, pelletized, and molded to give a test piece showing good heat resistance with short molding cycle time. It is stated that the addition of limonene in the base resin can improve the foaming ability of the base resin, and the molding time and cooling time can be shortened.
- the prior art does not provide for interpolymer particles comprising a polyolefin, e.g. polyethylene and an in situ polymerized vinyl aromatic resin forming an interpenetrating network of polyolefin and vinyl aromatic resin particles, and which particles contain a blowing aid that is not considered to be a hazardous air pollutant; that is considered as having a pleasant smell; and that is more effective as a blowing aid or plasticizer than those of the prior art.
- a polyolefin e.g. polyethylene and an in situ polymerized vinyl aromatic resin forming an interpenetrating network of polyolefin and vinyl aromatic resin particles, and which particles contain a blowing aid that is not considered to be a hazardous air pollutant; that is considered as having a pleasant smell; and that is more effective as a blowing aid or plasticizer than those of the prior art.
- the invention overcomes the above-described disadvantages of the prior art.
- the present invention provides foamable interpolymer resin particles comprised from 20% to 80% by weight of a polyolefin and from 80% to 20% by weight of a polymerized vinyl aromatic resin which form an interpenetrating network of polyolefin and vinyl aromatic resin particles.
- the foamable interpolymer resin particles are impregnated with a volatile hydrocarbon blowing agent and limonene as a blowing aid or plasticizer. Limonene is not considered to be a hazardous air pollutant; has a pleasant citrus smell; and improves the expandability of the interpolymer particles.
- the foamable interpolymer particles can be produced by suspending in an aqueous medium polyolefin particles; preferably adding a cross-linking agent to the polyolefin particles and from 25% to 400%, preferably 80% to 400%, by weight of vinyl aromatic monomer or monomer mixtures based on the weight of the polyolefin particles; adding a polymerization initiator to polymerize the vinyl aromatic monomer or monomer mixtures within the polyolefin particles to form an interpenetrating network of polyolefin and vinyl aromatic resin particles.
- the interpolymer particles are impregnated with a volatile, hydrocarbon blowing agent in an amount ranging from 1.5% to 20% by weight, preferably 1.5% to 15 % by weight, and more preferably, 5% to 15% by weight, based on the weight of the interpolymer particles, and limonene in an amount ranging from 0.1 to 5 parts, preferably 0.1 to 1.0 part based on 100 parts by weight of interpolymer particles.
- foamable interpolymer resin particles comprised of: 20% to 80% by weight polyolefin, preferably, cross-linked, and from 80% to 20% by weight of a polymerized vinyl aromatic resin, which form an interpenetrating network of polyolefin and vinyl aromatic resin particles; a blowing agent ranging from 1.5% to 20% by weight, preferably 1.5% to 15% by weight, and more preferably 5% to 15% by weight, based on the weight of the foamable interpolymer particles; and from 0.1 to about 5 parts, preferably 0.1 to 1 part (for 100 parts interpolymer particles) of limonene, as a plasticizer or blowing aid.
- limonene in the invention allows the blowing agent level to be reduced in the processing of the interpolymer particles and therefore the blowing agent level in the particles per se is reduced. This is particularly important when a volatile hydrocarbon blowing agent, e.g. pentane is used as a blowing agent in view of the environmental issues, e.g. emissions of the blowing agent, discussed hereinabove in the prior art section.
- a volatile hydrocarbon blowing agent e.g. pentane
- the polymerized vinyl aromatic resin is vinyl aromatic homopolymers, preferably, polystyrene, or polymerized vinyl aromatic copolymers, preferably, poly)styrene-butyl acrylate), and the polyolefin is polyethylene.
- foamable interpolymer resin particles comprising a blowing agent and limonene as a blowing aid or plasticizer which combination results in improved expandability of the resin particles in order to form articles with at least improved physical properties compared to that of the prior art.
- hazardous air pollutants such as toluene, benzene, etc.
- the interpolymer particles of the invention are comprised of polyolefin and in situ polymerized vinyl aromatic resin that form an interpenetrating network of polyolefin and vinyl aromatic resin particles.
- the interpolymer particles are impregnated with a blowing agent and limonene as a plasticizer or blowing aid.
- Such interpolymer particles can be obtained by processes described in the aforesaid U.S. Patent No. 3,959,189 and in U.S. Patent No. 4,168,353 (Kitamori ), both assigned to Sekisui Kaseihin Kogyo Kabushiki Kaisha.
- the process comprises suspending polyolefin particles and vinyl aromatic monomer or monomer mixtures in an aqueous suspension and polymerizing the monomer or monomer mixtures inside the polyolefin particles.
- U.S. Patent No. 3,959,189 and 4,168,353 however use toluene, benzene, 1,2-dichloropropane, etc as solvent in the impregnation step.
- the present invention particularly sets out to eliminate the use of HAPS chemicals, such as toluene and benzene, as a solvent or as a blowing aid.
- polyolefin as used herein is a plastic, which is prepared from at least one olefinic monomer, such as ethylene, propylene, butene, hexene or octene. In a preferred embodiment, the polyolefin is polyethylene.
- polyethylene as used herein includes not only a homopolymer of ethylene, but also an ethylene copolymer composed of at least 50 mole %, preferably at least 70 mole %, of an ethylene unit and a minor proportion of a monomer copolymerizable with ethylene, and a blend of at least 50% by weight, preferably at least 60% by weight, of the ethylene homopolymer or copolymer with another polymer.
- Examples of monomers copolymerizable with ethylene are vinyl acetate, vinyl chloride, propylene, butene, hexene, acrylic acid and its esters, methacrylic acid and its esters.
- the other polymer that can be blended with the ethylene homopolymer or copolymer may be any polymer compatible with it. Examples are polypropylene, polybutadiene, polyisoprene, polychloroprene, chlorinated polyethylene, polyvinyl chloride, a styrene/butadiene copolymer, a vinyl acetate/ethylene copolymer, an acrylonitrile/butadiene copolymer, a vinyl chloride/vinyl acetate copolymer, etc.
- polyethylene resin examples include low-, medium-, and high-density polyethylene, an ethylene vinyl acetate copolymer, an ethylene/propylene copolymer, a blend of polyethylene and polypropylene, a blend of polyethylene and an ethylene/vinyl acetate copolymer, and a blend of polyethylene and an ethylene/propylene copolymer.
- Ethylene-butyl acrylate copolymer and ethylene-methyl methacrylate copolymer can also be used.
- the amount of polyolefin in the interpolymer resin particles of the invention ranges from 20% to 80%, preferably 20% to 55%, by weight based on the weight of the interpolymer resin particles.
- the amount of polymerized vinyl aromatic resin in the interpolymer resin particles of the invention ranges from 20% to 80%, preferably from 45% to 80%, by weight based on the weight of the interpolymer resin particles.
- the vinyl aromatic resin can be polymerized monomers or the resin can be vinyl aromatic copolymers.
- vinyl aromatic monomers are styrene, alpha-methylstyrene, ethylstyrene, chlorostyrene, bromostyrene, vinyltoluene, vinylbenzene, and isopropylxylene. These monomers may be used either alone or in admixture.
- the vinyl aromatic copolymers can be similar to those disclosed in U.S Patent No. 4,049,594 (Ideka ) assigned to Sekisui Kaseihin Kogyo Kabushiki Kaisha. These copolymers are styrene copolymers prepared by the copolymerization of a styrene monomer with monomers such as 1,3-butadiene, alkyl acrylates (for example, butyl acrylate, ethyl acrylate and 2-ethylhexyl acrylate), alkyl methacrylates (for example, methyl methacrylate, ethyl methacrylate, butyl methacrylate and 2-ethylhexyl methacrylate) acrylonitrile, vinyl acetate, alpha-methylethylene, divinyl benzene, dimethyl maleate and diethyl maleate.
- alkyl acrylates for example, butyl acrylate, ethyl acrylate
- the vinyl aromatic resin is polystyrene or styrene-butyl acrylate copolymers.
- the interpolymer resin particles are formed as follows:
- the polyolefin particles are dispersed in an aqueous medium prepared by adding 0.01 to 5%, preferably 2 to 3%, by weight based on the weight of the water of a suspending agent such as water soluble high molecular weight materials, e.g., polyvinyl alcohol or methyl cellulose or slightly water soluble inorganic materials, e.g., calcium phosphate or magnesium pyrophosphate and soap, such as sodium dodecyl benzene sulfonate, and the vinyl aromatic monomers are added to the suspension and polymerized inside the polyolefin particles.
- a suspending agent such as water soluble high molecular weight materials, e.g., polyvinyl alcohol or methyl cellulose or slightly water soluble inorganic materials, e.g., calcium phosphate or magnesium pyrophosphate and soap, such as sodium dodecyl benzene sulfonate, and the vinyl aromatic mono
- any of the conventionally known and commonly used suspending agents for polymerization of the vinyl aromatic monomers can be employed. These agents are well known in the art and can be freely selected by one skilled in the art.
- the water is in an amount generally from 0.7 to 5, preferably 3 to 5 times that of the starting polyolefin particles employed in the aqueous suspension, on a weight basis, and gradually the ratio of the polymer particles to the water may reach around 1:1.
- the polymerization of the vinyl aromatic monomers, which is absorbed in the polyolefin particles, is carried out using initiators.
- the initiators suitable for suspension polymerization of the vinyl aromatic monomers are generally used in an amount of 0.05 to 2 percent by weight, preferably 0.1 to 1 percent by weight, based on the weight of the vinyl aromatic monomer.
- suitable initiators include organic peroxides such as benzoyl peroxide, lauroyl peroxide, t-butyl perbenzoate and t-butyl perpivalate and azo compounds such as azobisisobutylonitrile and azobisdimethylvaleronitrile.
- initiators can be used alone or two or more initiators can be used in combination. It is preferred that the initiators be dissolved in the vinyl aromatic monomers, which are to be absorbed in the polyolefin particles. This differs from that of the aforesaid U.S. Patent Nos. 3,959,189 and 4,168,353 , which dissolve the initiator in a solvent, e.g. toluene, benzene, and 1,2-dichloropropane. The invention sets out to eliminate the use of these solvents.
- a solvent e.g. toluene, benzene, and 1,2-dichloropropane.
- the polymerized vinyl aromatic resin is uniformly dispersed inside the polyolefin particles.
- cross-linking is done simultaneously with the polymerization of the vinyl aromatic monomer in the polyolefin particles, and before impregnation of the blowing agent and the limonene.
- cross-linking agents are used.
- Such cross-linking agents include di-t-butylperoxide, t-butyl-cumylperoxide, dicumyl-peroxide, ⁇ , ⁇ -bis-(t-butylperoxy)-p-diisopropylbenzene, 2,5-dimethyl-2,5-di-(t-butylperoxy)-hexyne-3,2,5-dimethyl-2,5-di-(benzoylperoxy)-hexane and t-butylperoxyisopropyl-carbonate.
- cross-linking agents are absorbed in the polyolefin particles together with the vinyl aromatic monomers by dissolving the cross-linking agent in an amount of 0.1 to 2 weight%, preferably 0.5 to 1 weight %, based on the weight of the polyolefin particles suspended in water. Further details of the cross-linking agents and the manner for absorbing the cross-linking agents into the polyolefin particles are given in the aforesaid U.S. Patent No. 3,959,189 .
- the resulting interpolymer can be used as raw materials in producing foamed articles.
- the blowing agent and the limonene are introduced into the interpolymer resin particles to form foamable or expandable interpolymer particles, which in turn, are used to mold foamed articles.
- the blowing agent should have a boiling point lower than the softening point of the polyolefin and should be gaseous or liquid at room temperature (about 20 to 30°C) and normal pressure (about atmospheric). Blowing agents are well known in the art and generally have boiling points ranging from - 42°C to 80°C, more generally, from -10°C to 36°C.
- Suitable hydrocarbon blowing agents include aliphatic hydrocarbons such as n-propane, n-butane, iso-butane, n-pentane, iso-pentane, n-hexane, and neopentane, cycloaliphatic hydrocarbons such as cyclobutane and cyclopentane, and halogenated hydrocarbons such as methyl chloride, ethyl chloride, methylene chloride, trichlorofluoromethane, dichlorofluoromethane, dichlorodifluoromethane, chlorodifluoromethane and dichlorotetrafluoroethane, etc.
- aliphatic hydrocarbons such as n-propane, n-butane, iso-butane, n-pentane, iso-pentane, n-hexane, and neopentane
- blowing agents can be used alone or as mixtures. If n-butane, ethyl chloride, and dichlorotetrafluoroethane, which are gaseous at room temperature and normal pressure, are used as a mixture, it is possible to achieve foaming to a low bulk density.
- the specific types of volatile blowing agents are taught in the aforesaid U.S. Patent No. 3,959,180 .
- the blowing agent is selected from the group consisting of n-pentane, iso-pentane, neopentane, cylcopentane, and mixtures thereof.
- the amount of the blowing agent ranges from 1.5% to 20% by weight, preferably 1.5% to 15 % by weight, more preferably from 5% to 15% by weight, based on the weight of the interpolymer particles.
- Limonene is used in combination with the blowing agent and as stated herein above, acts as a plasticizer or blowing aid in the invention.
- Limonene is a mono-terpene hydrocarbon existing widely in the plant world.
- the known types are d-limonene, 1-limonene, and dl-limonene.
- D-limonene is contained in the skin of citrus fruits and is used in food additives as a fragrant agent; its boiling point is about 176°C; and its flammability is low.
- D-limonene is a colorless liquid, has a pleasant orange-like aroma, is approved as a food additive, and is widely used as a raw material of perfume.
- limonene is not a hazardous air pollutant.
- Limonene is used in the invention to replace benzene, toluene, etc., as blowing aids disclosed in the aforesaid U.S. Patent No. 4,429,059 .
- the amount of limonene ranges from 0.1 to 5 parts, preferably 0.1 to 1 part, by weight per 100 parts by weight of the foamable interpolymer resin particles.
- the interpolymer particles of the invention may be conveniently produced as follows: In a first reactor, the polyolefin particles are suspended in an aqueous medium containing a dispersing agent.
- the dispersing agent may be polyvinyl alcohol, methylcellulose, calcium phosphate, magnesium pyrophosphate, calcium carbonate, tricalcium phosphate, etc.
- the amount of dispersing agent employed is 0.01 to 5% by weight based on the amount of water.
- a surfactant may be added to the aqueous medium. Generally, the surfactant is used to lower the surface tension of the suspension and helps to emulsify the water/vinyl aromatic monomer in mixture in the initiator and wax mixes, if used.
- a suitable wax would be ethylene bistearamide.
- the aqueous medium is generally heated to a temperature at which the vinyl aromatic monomers can be polymerized, i.e. from about 60°C to about 120°C over a period of time, for example, 12 to 20 hours. Over this 12 to 20 hour period, the vinyl aromatic monomers, the vinyl aromatic polymerization initiator, and the cross-linking agent are added to the resulting suspension containing the polyolefin particles, which are dispersed in the aqueous medium. These materials may be added all at one time, or gradually in individual portions.
- the interpolymer particles are acidified, dewatered, screened, and subsequently charged to a second reactor where the particles are impregnated with the blowing agent and the limonene.
- the impregnation step is carried out by suspending the interpolymer particles in an aqueous medium, adding the blowing agent and limonene to the resulting suspension, and stirring at a temperature of, preferably, about 40°C degrees to 80°C.
- the blowing agent and the limonene can be blended together and then added to the interpolymer particles or can be added to the interpolymer particles separately.
- blowing agent and the limonene can be added to the first reactor during or after the polymerization process.
- the above processes describe a wet process for impregnation of the interpolymer particles.
- the interpolymer particles can be impregnated via an anhydrous process similar to that taught in Column 4, lines 20-36 of the aforesaid U.S. Patent No. 4,429,059
- the interpolymer resin particles may also contain an anti-static additive; a flame retardant; a colorant or dye; and a filler material; other additives such as chain transfer agents, suitable examples including C 2-15 alkyl mercaptans, such as n-dodecyl mercaptan, t-dodecyl mercaptan, t-butyl mercaptan and n-butyl mercaptan, and other agents such as pentaphenyl ethane and the dimer of ⁇ -ethyl styrene; and nucleating agents, such as polyolefin waxes, i.e. polyethylene waxes.
- chain transfer agents suitable examples including C 2-15 alkyl mercaptans, such as n-dodecyl mercaptan, t-dodecyl mercaptan, t-butyl mercaptan and n-butyl mercaptan,
- interpolymer particles comprised of 30% by weight polyethylene and 70% by weight of an in situ polymerized styrene-butyl acrylate copolymer inside the polyethylene particles were charged into a 95 litre (25-gallon) reactor for impregnation.
- This reactor contained 42 kg (93 pounds) of deionized water, and 5 grams of Calsoft F90 (sodium dodecyl benzene sulfonate), a surfactant.
- the interpolymer particles were produced according to the process taught in the aforesaid U.S. Patent No. 3,959,189 .
- d-limonene which is Technical Grade (95% purity) from Florida Chemical Company
- isopentane 13% by weight
- the expandability of the resultant foamed particles was measured by the minimum bulk density, which is achieved as the particles are processed in a single pass through a TRI 502 continuous steam expander.
- the resulting particles had a more pleasant smell, i.e. an orange blossom fragrance, compared to the interpolymer particles of the prior art.
- the foamed particles produced in the Example were dried out and then molded into 61 cm x 61 cm x 5.1 cm (24 inch x 24 inch x 2 inch) rectangular samples.
- the machine was a Kohler General KG 606 steam molding press.
- the physical properties were measured and/or tested according to the standards set up by ASTM D3575. These properties appear in the Table below.
- the interpolymer particles of the invention containing d-limonene are compared to the interpolymer particle of the prior art, where ethylbenzene was used as the blowing aid.
- the interpolymer particles of the invention can use a lower amount of blowing aid, i.e. 0.35 pph (invention) vs. 0.50 pph (for the particles using ethylbenzene as the blowing aid), and can obtain a lower minimum achievable density compared to the particles of the prior art; that is, 18.42 kg/m 3 for the interpolymer particles of the invention vs. 19.22 kg/m 3 for the particles of the prior art using ethylbenzene.
- the values for the properties of the interpolymer particles of the invention using d-limonene show an improvement compared to those for conventional interpolymer particles using ethylbenzene as the blowing aid.
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- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US44276103P | 2003-01-27 | 2003-01-27 | |
US442761P | 2003-01-27 | ||
PCT/US2004/001824 WO2004069917A2 (en) | 2003-01-27 | 2004-01-23 | Foamable interpolymer resin particles containing limonene as a blowing aid |
Publications (3)
Publication Number | Publication Date |
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EP1587861A2 EP1587861A2 (en) | 2005-10-26 |
EP1587861A4 EP1587861A4 (en) | 2006-03-22 |
EP1587861B1 true EP1587861B1 (en) | 2012-04-11 |
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Application Number | Title | Priority Date | Filing Date |
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EP04704842A Expired - Lifetime EP1587861B1 (en) | 2003-01-27 | 2004-01-23 | Foamable interpolymer resin particles containing limonene as a blowing aid |
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US (1) | US6908949B2 (zh) |
EP (1) | EP1587861B1 (zh) |
JP (1) | JP2006515648A (zh) |
KR (1) | KR20050104355A (zh) |
CN (1) | CN100339423C (zh) |
AT (1) | ATE553147T1 (zh) |
AU (1) | AU2004209533B2 (zh) |
BR (1) | BRPI0406930B8 (zh) |
CA (1) | CA2513266C (zh) |
MX (1) | MXPA05007777A (zh) |
NO (1) | NO20053653L (zh) |
PL (1) | PL209097B1 (zh) |
WO (1) | WO2004069917A2 (zh) |
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- 2004-01-23 MX MXPA05007777A patent/MXPA05007777A/es active IP Right Grant
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- 2004-01-23 AT AT04704842T patent/ATE553147T1/de active
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- 2004-01-23 WO PCT/US2004/001824 patent/WO2004069917A2/en active Application Filing
- 2004-01-23 JP JP2006502952A patent/JP2006515648A/ja active Pending
- 2004-01-23 PL PL377254A patent/PL209097B1/pl unknown
- 2004-01-23 BR BRPI0406930A patent/BRPI0406930B8/pt active IP Right Grant
- 2004-01-23 KR KR1020057013688A patent/KR20050104355A/ko active Search and Examination
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BRPI0406930A (pt) | 2006-01-03 |
CN1745130A (zh) | 2006-03-08 |
NO20053653D0 (no) | 2005-07-27 |
NO20053653L (no) | 2005-08-25 |
CA2513266A1 (en) | 2004-08-19 |
US6908949B2 (en) | 2005-06-21 |
AU2004209533B2 (en) | 2008-10-02 |
ATE553147T1 (de) | 2012-04-15 |
WO2004069917A3 (en) | 2004-09-23 |
PL209097B1 (pl) | 2011-07-29 |
WO2004069917A2 (en) | 2004-08-19 |
CA2513266C (en) | 2012-01-03 |
JP2006515648A (ja) | 2006-06-01 |
US20040152795A1 (en) | 2004-08-05 |
EP1587861A2 (en) | 2005-10-26 |
PL377254A1 (pl) | 2006-01-23 |
CN100339423C (zh) | 2007-09-26 |
EP1587861A4 (en) | 2006-03-22 |
BRPI0406930B1 (pt) | 2014-08-26 |
MXPA05007777A (es) | 2005-09-30 |
KR20050104355A (ko) | 2005-11-02 |
BRPI0406930B8 (pt) | 2022-08-02 |
AU2004209533A1 (en) | 2004-08-19 |
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